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GER-3936A
GE Power Systems
ii
To Stack
Cooling Air Cooling System
Attemp
Filter
HP
IP
LP
LP
Generator
Feedwater Pump
Gas Turbine
LEGEND Steam Water Exhaust Air Fuel
Air Treatment
Filter B
Condensate Filter
Figure 2. STAG 107H/109H cycle diagram heater to pre-heat the fuel gas supplied to the combustion system. The water leaving the fuel heater is returned to the cycle through the condensate receiver to the condenser. ture effect on performance for the STAG 107H as well as the part load performance. The graphs in Figure 4 show the ambient temperature effect on performance for the STAG 109H as well as the part load performance. The low NOx emissions are achieved by a Dry Low NOx (DLN) combustion system. The closed circuit steam-cooling system also contributes to the low NOx emissions because a minimum of air bypasses the combustors for cooling the gas turbine hot gas path parts.
NOx Emissions ppmvd at 15% O2 <9 < 25
Performance
The rating point thermal and environmental performance is summarized in Table 1 for the advanced technology single-shaft combinedcycle units burning natural gas fuel. The graphs in Figure 3 show the ambient tempera-
Combined-Cycle Net Unit Power, MW STAG 107H STAG 109H 400 480
Net Heat Rate (LHV) BTU/kWh kJ/kWh 5,687 5,687 6,000 6,000
Thermal Discharge to Cooling Water BTU/kWh kJ/kWh 1,790 1,790 1,888 1,888
Notes: 1. Ambient Air Conditions = 15C (59F), 1.0133 barA (14.7 psia), 60% RH 2. Steam Turbine Exhaust Pressure = 0.04064 barA, (1.2 In HgA) 3. Performance is net plant with allowances for equipment and plant auxiliaries with a once-through cooling water system 4. Three-Pressure, Reheat, Heat Recovery Feedwater Heating Steam Cycle
Table 1. Advanced technology combined cycle thermal and environmental performance GE Power Systems GER-3936A (10/00)
s s
120%
102.0%
160%
115%
101.5%
150%
110%
101.0%
140%
100.5%
130%
Basis: 15C (59F) ambient temperature, 1.013 BarA (14.7 psia) ambient pressure, 60% relative humidity, 0.0508 BarA (1.5" HgA) ST exhaust pressure, 2 x 851mm (33.5") LSB
120%
100% Power Basis: 15C (59F) ambient temperature, 1.013 BarA (14.7 psia) ambient pressure, 60% relative humidity, 0.0508 BarA (1.5" HgA) ST exhaust pressure, 2 x 851mm (33.5") LSB 0 10 20 30 40 50 60 70 80
100.0%
110%
95%
99.5%
100%
90%
99.0%
90%
85%
98.5%
80% 10.0%
80% 90 100
98.0% 110
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
Figure 3. S107H ambient temperature effect on performance and part load performance
125%
102.5%
170%
120%
102.0%
160%
115%
101.5%
150%
101.0%
140%
Basis: 15C (59F) ambient temperature, 1.013 BarA (14.7 psia) ambient pressure, 60% relative humidity, 0.0508 BarA (1.5" HgA) ST exhaust pressure, 2 x 851mm (33.5") LSB
105%
100.5%
130%
100% Power Basis: 15C (59F) ambient temperature, 1.013 BarA (14.7 psia) ambient pressure, 60% relative humidity, 0.0508 BarA (1.5" HgA) ST exhaust pressure, 2 x 851mm (33.5") LSB 0 10 20 30 40 50 60 70 80 90 100
100.0%
120%
95%
99.5%
110%
90%
99.0%
100%
85%
98.5%
90%
80%
98.0% 110
80% 10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
Figure 4. S109H ambient temperature effect on performance and part load performance
HP Throttle Pressure (psig/Barg) Temperature (F/C) Hot Reheat Pressure (psig/Barg) Temperature (F/C) LP Admission Pressure (psig/Barg) Temperature (F/C) Exhaust Pressure Pressure (in. HgA/barA)
Steam Turbine
A wide range of steam turbines are available to suit specific site, duty and economic requirements for both 50 Hz and 60 Hz applications while satisfying all of the combined-cycle integration requirements. Since there are no extractions for feedwater heating and since steam is generated and admitted to the turbine at three pressures, the flow at the exhaust is approximately 30% greater than the throttle flow. The last stage generates up to 15% of the steam turbine output, so the efficiency of the turbine's last stage and the sizing of the exhaust annulus area are particularly important for all combined-cycle applications. The range of site-
Frequency
Length
Pitch Diameter
Exhaust annulus Area for Number of Parallel Flows 1 1 Sq Ft 2 Sq M 12.28 8.11 87.3 16.22 13.51 9.4 101.2 18.80 2 Sq Ft 132.2 174.6 145.4 202.4
Hz/RPM 60/3600
mm 851 1016
Sq M
50/3000
851 1067
Table 3. Last-stage buckets for advanced technology combined-cycle applications GE Power Systems GER-3936A (10/00)
s s
COL. COL.
HP
LP
IP
GEN.
COL. COL.
HP
IP
LP
GEN.
THRUST THRUST BEARING BEARING KEY SHAFT KEY FOR SHAFT POSITION FOR POSITION
TWO TWO FLOW, FLOW, DOWN EXHAUST EXHAUST DOWN BEARING BEARING
Figure 5. S107H and S109H single-shaft STAG equipment configuration ical integration as a single prime mover with a single thrust bearing, thus minimizing the overall machine length. Use of all solid rotor couplings provides maximum reliability and simplifies the control, overspeed protection, and auxiliary systems. The thrust bearing is located in the gas turbine inlet end bearing housing, which permits independent operation of the gas turbine for testing in the factory. This location is at the high pressure end of the steam turbine, which minimizes differential expansion and permits use of small axial clearances throughout the HP and IP sections. The steam turbine contribution to the shaft thrust load is low and in the opposite direction to that of the gas turbine, so that the thrust bearing is lightly loaded under all operating conditions. A single lubricating oil system with AC- and DCpowered pumps provides oil to all shaft bearings and to the generator hydrogen seals. Similarly, a single high-pressure hydraulic fluid system is used for all control and protective devices. GE Power Systems GER-3936A (10/00)
s s
Features:
1. Steam turbine installed between the gas turbine and the field assembled hydrogen-cooled generator. 2. Solid coupling between gas turbine and steam turbine. Direct coupled steam turbine shafts and direct coupled steam turbine to generator. 3. Single thrust bearing in the gas turbine compressor to fix shaft position in conjunction with tie rod installation between the steam turbine front standard and the gas turbine compressor inlet casing. 4. Steam turbine front standard keyed to foundation. 5. Common lube oil system with hydrogen seal oil system. Common fire-resistant hydraulic oil system. 6. Static start (LCI). 7. Turning gear mounted between steam turbine and generator 5
Mechanical Outline, One-Line Diagram, Device Summary, Piping Schematics (Lube Oil, Hydraulic). The selection of the single shaft as the preferred configuration for the advanced technology combined cycles is based on the extensive experience since its introduction by GE in 1968. Table 4 presents the operating experience on 86 GE single-shaft combined-cycle units with nearly 18,000 MW of installed capacity.
Steam-Cooling System
The gas turbine steam cooling system is integrated with the steam bottoming cycle to reliably provide cooling steam at all operating conditions. The normal supply of cooling steam is from the outlet of the HRSG IP superheater, supported as necessary with HP steam turbine exhaust. The steam is delivered to the gas turbine stationary parts through casing connections and to the rotor through a conventional gland connection. The cooling steam is returned to the steam cycle at the cold reheat
Rating (MW) Unit 21 11 21 11 72 83 93 165 112 125 50 138 350 350 343 235 340 248 253 360 110 360 407 Plant 21 11 21 11 290 250 278 2310 560 750 50 690 1400 1400 2742 1645 2720 248 253 1440 110 360 407 17,967 Gas Turbine MS5001 MS3002 MS5001 MS3002 MS7001B MS7001C MS7001E MS9001E MS7001E MS7001E MS6001B MS7001EA MS9001F MS9001FA MS9001FA MS7001FA MS9001FA MS7001FA MS7001FA MS9001FA MS6001FA MS9001FA MS9001FA Commercial Operation 1968 1969 1972 1972 1974 1976 1977 1986 1988 1990 1990 1992 1995 1995 1997 1998 1996 1996 1997 1999 1998 1999 2001
Utility Wolverine Electric City of Ottawa City of Clarksdale City of Hutchinson Salt River Projects Arizona Public Ser. Western Farmers Tokyo Electric Chubu Electric Chugoku Electric Ministry of Pet. Kyushu Electric Power Gen EPON Tokyo Electric Chubu Electric China Light & Power Crocket Cogen Cogentrix Tokyo Electric Boffolora Akzo Great Yarmouth Total
Site Michigan, USA Ottawa, KS, USA Clarksdale, MS, USA Hutchinson, MN, USA Santan, AZ, USA Phoenix, AZ, USA Anadarko, OK, USA Futtsu, Japan Yokkiachi, Japan Yanai, Japan Lama Dien, China Shin-Oita, Japan Connahs Quay, UK Netherlands Yokohama, Japan Kawagowe, Japan Black Point, Hong Kong Calif, USA Clark County, WA Chiba, Japan Italy Delesto II, Netherlands Great Yarmouth, UK
extraction after the first superheater pass is used to cool the LP steam turbine from ~70% speed until steam turbine loading is underway. Figure 2 includes a diagram of the three-pressure, reheat HRSG. While the system can be configured with either forced or natural circulation evaporators, Figure 2 shows a system with natural circulation evaporators. The HRSG is a typical three-pressure, reheat HRSG that is commonly applied in combined cycles. It includes the following features to accommodate the steam cooling system: s The reheater size is reduced since part of the reheating is performed by the gas turbine cooling steam system. s The reheater is located in the gas path downstream of the high temperature section of the HP superheater. The reheater receives steam during all operating modes except at very low loads during startup, prior to availability of IP steam. s HP steam is extracted after the first pass of the HP superheater during low load operation to establish gas turbine steam cooled operation before the steam turbine is loaded and provide cooling steam to the LP steam turbine above ~70% speed. s Control of the HP steam temperature is accomplished by a steam attemperation system which bypasses a section of the HP superheater. This system eliminates the potential for dissolved contaminants to enter the steam as can occur with attemperation with feedwater. Attemperation steam is extracted after it passes through one pass in the superheater to assure that it will be dry after the small pressure drop across the steam control valve. 7
steam supply to the gas turbine. This device will operate at least 24,000 hours without maintenance when provided with steam meeting the system purity requirements. The upstream system design features and associated protective strategies provide a means of assuring the design life of the steam filter. Figure 6 presents the location of the steam and water sampling points within the S107H and S109H combined-cycle systems. All sampling probes and instrumentation (including a sampling panel) are of high sensitivity and reliable design. Steam and water conductivity, pH, and sodium measurements are continuously sampled and monitored. Other measurements not required for plant protection are monitored intermittently.
1 CC
Dis. O2
Cooling Water
DP
Hotwell 2 SC
Filter A
Filter B
Legend: SC - Specific Conductivity CC - Cation Conductivity Na - Sodium Analyzer D.Ox - Dissolved Oxygen Si - Silica Analyzer pH All samples are taken on continuous basis Note: All HRSG sampling requires cooling and temperature compensation, minimize time for sampling process
Figure 6. Steam and water sampling schematic GE Power Systems GER-3936A (10/00)
s s
Log Printer
Operator Station
Operator Station
Engineering Workstation
Historian
Peer-to-Peer Communications Time Synchronized Unit Controls Time Coherent System Data
Static Starter
HMI/ Server
Alarm Printer
Figure 7. Single-shaft combined-cycle unit integrated control architecture A redundant data highway connects all control components with the central control room consoles. Historical archival and retrieval of plant data assists performance optimization and equipment maintenance. Time synchronization of all control components provides time coherent, time tagged data for process monitoring, historical archival, sequence of events logging, real time trending and comprehensive alarm management. High speed communication interfaces link the plant control to external dispatch and control systems. The control and protection strategies are integrated between all components of the system. High levels of fault tolerance maximize unit starting and running reliability for both base GE Power Systems GER-3936A (10/00)
s s
plant level control. Windowed displays enable the operator to constantly monitor the desired process and simultaneously view detailed popup windows to trend equipment operating data or diagnose process problems. An engineering workstation enables the operator to configure and tune control loops, perform detailed control and process diagnostics, maintain software, manage the system configuration and generate operation reports. The ICS is designed with dedicated I/O (inputs/outputs) to control the engineered equipment packages. In addition, it has the flexibility and expandability needed to address additional I/O requirements to satisfy individual owner requirements. This includes both 9
Gateway
Static Starter
HRSG/MA Generator Steam Turbine Redundant Unit Data Highway #2 Gas Turbine
BOP Equipment
Operator Station Generator Excitation & Protection Static Starter Steam Turbine & Bypass Control Gas Turbine & Cooling Steam Control HRSG & Steam Cycle Mechanical Auxiliaries Balance Of Plant Operator Station Alarm Printer
Gas Turbine
BOP Equipment
Figure 8. Multiple-unit station control architecture redundant and non-redundant I/O which is integrated with serial remote I/O (e.g. GENIUS, Fieldbus) and connections to programmable logic control systems. All I/O points are available to the controls database for the integrated system. The speed and load control for the unit operates through control of the gas turbine fuel valves. The steam turbine control valves are closely coordinated, being closed at startup until steam at sufficient pressure and temperature for admission is available from the HRSG. They are then ramped open and held in fixed position as load is changed with sliding pressure. The steam turbine control valves do not participate in normal frequency control. The HP and LP control valves begin to close when speed rises to 103% of rated speed and are fully closed at 105%. The intercept valves operate in a pressure control mode at low load to maintain proper steam pressure in the gas turbine steam cooling system. With increasing speed the intercept valves lag the control valves by 2% speed, beginning to GE Power Systems GER-3936A (10/00)
s s
close at 105% rated speed and reaching the fully closed position at 107% of rated speed. This normal governing characteristic is overridden by a power/load unbalance-sensing feature upon the sudden loss of significant electrical load. Pressure in a steam turbine stage, representative of steam turbine output, is summed with a gas turbine fuel flow signal and continuously compared with the generator electrical output. When a significant imbalance of power generated over electrical output is detected the control and intercept valves are closed as rapidly as possible, limiting the speed rise to less than the 110% setting of the emergency overspeed trip. Ultimate protection against excessive overspeed is provided by the emergency governor that trips the unit by simultaneously closing all gas turbine fuel and steam turbine control and stop valves. The sequencing system automatically starts the unit from a ready-to-start condition and loads it to gas turbine base load or a preset load. Table 5 shows starting time from initiation to full load. Figure 9 presents an overview of the starting and 10
Plant Arrangement
The high power density of the advanced technology combined-cycle systems enables a compact plant arrangement. Typical plan and elevation arrangements are shown in Figure 11 with overall dimensions for outdoor STAG 107H and STAG 109H plants. In this arrangement, the
110 100 90 80
Normal loading 70 60
OUTPUT
50 40 30 20 10 0 0 5 10 15 20 25
SPEED
30
35
40
45
50
55
60
65
70
75
Figure 9. Typical S107H/S109H hot start loading profile GE Power Systems GER-3936A (10/00)
s s
11
90 80 70 60 50
Normal loading
SPEED
40 30 20
Basis:
Single unit with auxiliary boiler sized for steam seals and condenser purge only.
180
195
210
225
240
Figure 10. Typical S107H/S109H cold start loading profile, single unit
Multi-Shaft STAG 107H (One GT/ST) 1 1 1 1 2 2 2 0 1 2 1 0 High/Low High Simple Simple Good Complex Yes Yes
STAG 107H Single Shaft Equipment (Quantity) Gas Turbine Steam Turbine Condenser Cooling Water Trains Generators Main Electrical Connections Generator Transformers Steam Valves (Quantity) Main Steam Non-Return Reheat Isolation Reheat Relief Reheat Stop/Control Low Pressure Non-Return Foundations Installed Cost Operation Combined-Cycle Start/Stop Load Following Contingency Management Islanding Simple Cycle Staged Construction 1 1 1 1 1 1 1 0 0 2 1 0 High Low Simple Simple Good Simple Good No No
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The capacities and efficiencies are shown as ranges because they vary with plant economic considerations and the type of gasifier, gas cleanup system, air and steam cycle integration and the coal or other solid fuel analysis and moisture content. Key features of an advanced technology IGCC plant that enable economical power generation are: s Low installed cost resulting from the capacity of the unit which enables it to be matched with a single large gasifier. s High efficiency which reduces fuel consumption and further reduces plant cost by reducing the capacity of the gasification and cleanup system per unit of installed generation capacity.
Repowering
The advanced technology combined-cycle system is readily adaptable to the repowering of existing steam turbine generator units. The
A C B
Figure 11. Single-shaft unit plan and elevation GE Power Systems GER-3936A (10/00)
s s
13
Air
Gasifier
Gas Cooler
Gas Cleanup
I.P. L.P.
Air Exh. Gas Nitrogen Coal Coal Gas Steam Water Oxygen
Air
Gas Turbine
Steam Turbine
Generator
Electric Power
Figure 12. Unitized advanced technology IGCC system integration of the steam cycle with the gas turbine cooling system requires appropriate consideration, but several methods for matching the cooling requirements to the existing steam cycle are available and include the following: s The cooling steam temperature and pressure for the MS7001H and MS9001H gas turbines are in the same range as those of the cold reheat steam in many conventional steam units with 2400 psig (165 bar) throttle pressure. s Apply cooling water and existing support facilities and replace the existing steam turbine with a modern, high efficiency steam turbine that is specifically matched to the combinedcycle requirements. This option is attractive when the use of existing water permits can minimize site permitting work. A wide range of steam turbine ratings can be matched to the MS7001H and MS9001H gas turbines by retaining existing feedwater heaters as may be necessary to meet exhaust flow limitations.
Conclusion
The GE advanced technology combined cycles promise improved economics of electric power generation with outstanding environmental performance in natural gas and coal-fired applications. These characteristics are enhanced by the evolutionary development from a technology base with extensive experience, which assures low maintenance and reliable, convenient operation.
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Figure 10. Typical S107H/S109H cold start loading profile, single unit Figure 11. Single-shaft unit plan and elevation Figure 12. Unitized advanced technology IGCC system
List of Tables
Table 1. Table 2. Table 3. Table 4. Table 5. Table 6. Table 7. Advanced technology combined-cycle thermal and environmental performance Advanced technology combined-cycle steam conditions Last-stage buckets for advanced technology combined-cycle applications Single-shaft combined-cycle experience Starting time from initiation to full load Combined-cycle configuration comparison summary Ratings for advanced technology IGCC plants
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